Systems and methods for constructing temporary, re-locatable structures

ABSTRACT

A system and method for constructing a temporary structure is disclosed. The system comprises a plurality of wall panels, a plurality of roof panels, a plurality of floor panels, at least one door panel, and each wall panel, roof panel, floor panel, and door panel comprising at least one edge coupled to a first track and at least one edge coupled to a second track. The first track has a first surface with an indentation and a flat second surface. The second track has an angled hemmed tab extending therefrom that is adapted to mate with the indentation of the first track and a straight hemmed tab extending therefrom that is adapted to abut the flat second surface of the first track.

REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional Application Ser. No. 61/489748, filed May 25, 2011, entitled “Systems and Methods for Constructing Temporary, Re-locatable Structures,” which is hereby specifically and entirely incorporated by reference.

BACKGROUND

1. Field of the Invention

The invention is directed to systems and methods of constructing temporary or re-locatable structures and, in particular, systems and methods of constructing temporary structures to be energy efficient using insulated panels.

2. Background of the Invention

Global warming, high energy costs, lack of reusable sources of energy, and diminishing resources of fossil fuels are all reasons, among others, to improve the energy efficiency of structures. Traditional temporary structures, such as tents, collapsible fabric or metal structures, or plastic structures, are usually energy inefficient, losing hot and/or cool air though the various surfaces, walls, roofs, windows, doors, gaps, and other components.

In order to improve the energy efficiency of these temporary buildings it is often necessary to retrofit the building with energy efficient materials, for example with spray-on insulation. Such upgrading is costly, time consuming, and can ruin the structure or re-locatable. Furthermore, existing temporary structures often are difficult to assemble, having multiple parts that must be sorted, organized and installed.

Therefore, it is desirable to have systems and methods of constructing a temporary structure that is cost effective, easy to install, and provides energy efficiency.

SUMMARY OF THE INVENTION

The present invention overcomes the problems and disadvantages associated with current strategies and designs and provides new systems and methods of constructing temporary or re-locatable structures.

A system and method for constructing a temporary or re-locatable structure is disclosed. The system comprises a plurality of side panels and a plurality of roof and floor panels and a plurality of a first track and a plurality of a second track, the first track having an indentation and the second track having a hemmed tab that is adapted to mate with the indentation of the first track. Each side panel has a first edge coupled to a first track and a second, parallel edge coupled to a second track, while each roof and floor panel has two edges coupled to two first tracks and two edges coupled to two second tracks.

Other embodiments and advantages of the invention are set forth in part in the description, which follows, and in part, may be obvious from this description, or may be learned from the practice of the invention.

DESCRIPTION OF THE DRAWINGS

The invention is described in greater detail by way of example only and with reference to the attached drawings, in which:

FIG. 1 depicts an embodiment of a wall of side panels.

FIG. 2 depicts an embodiment of interlocking tracks.

FIG. 3 depicts an embodiment of top and bottom tracks.

FIG. 4 depicts another embodiment of a wall of side panels.

FIG. 5 depicts a plan for an embodiment of a temporary structure.

FIG. 6 depicts an embodiment of coupling perpendicular side panels.

FIG. 7 depicts an embodiment of roof and floor panels.

FIG. 8 depicts an embodiment of an exterior wall.

FIGS. 9 a-b depict an embodiment of coupling a wall panel to a floor panel.

FIGS. 10 a-b depict an embodiment of coupling a wall panel to a roof panel.

FIGS. 11 a-b depict an embodiment of coupling a wall panel to a roof panel.

FIGS. 12 a-b depict an embodiment of coupling two roof panels and a roof beam.

FIGS. 13 a-b depict an embodiment of coupling a wall panel to a floor panel.

FIGS. 14 a-b depict an embodiment of coupling a wall panel to a floor panel.

FIGS. 15 a-b depict an embodiment of the elements of an exemplary structure contained within a standard shipping container.

DESCRIPTION OF THE INVENTION

As embodied and broadly described herein, the disclosures herein provide detailed embodiments of the invention. However, the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, there is no intent that specific structural and functional details should be limiting, but rather the intention is that they provide a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.

A problem in the art capable of being solved by the embodiments of the present invention is constructing a temporary, re-locatable structure that is energy efficiency. It has been surprisingly discovered that by using interlocking brackets and insulating panels an energy efficient temporary structure can be constructed more easily and quickly than a traditional temporary structure.

FIG. 1 depicts an exemplary exterior wall 100. In the preferred embodiment, wall 100 is comprised of a plurality of panels 105. As shown in FIG. 1, panels 105 are 8 feet wide by 8.5 feet tall; however other size panels can be used. Preferably each panel 105 is comprised of a polystyrene core; however, other insulating materials such as, but not limited to, fiberglass, urea-formaldehyde, cellulous, and polyethylene can be used. Additionally, panels 105 may be coated with FRP (fiberglass reinforced plastic) boards, film coverings (e.g. graphical image film coverings or heat dissipating film coverings), spray coatings (e.g. insulating spray coatings or fire retardant spray coatings), Strongwell's Safe Plates, or other materials. Panels 105 are preferably also made of a fire retardant material. Preferably, panels 105 have a thickness of either 3.5 inches, 5.5 inches, or 7.5 inches; however other thicknesses are possible. In the preferred embodiment, panels 105 weigh no more than 1.625 pounds per square foot; however other weights are possible.

FIG. 2 depicts exemplary interlocking tracks 210 a (labeled A in the figures) and 210 b (labeled B in the figures). In the preferred embodiment, each panel 105 has one track 210 a coupled to a first edge and one track 210 b coupled to a second, parallel edge. In the preferred embodiment, tracks 210 a and 210 b are coupled to the long sides of panels 105, however, depending on the structure, the short sides of panels 105 can be coupled to tracks 210 a and 210 b. Furthermore, in certain embodiments each panel can have two tracks 210 a and two tracks 210 b. Preferably in embodiments with tracks on each edge of the panel 105, the two tracks 210 a are adjacent to each other and the two tracks 210 b are adjacent to each other such that opposing edges have different tracks. Track 210 a has indented or recessed portion 215 along its outer edge, into which angled hemmed tab 220 of track 210 b mates. On the opposite edge of track 210 b from angled hemmed tab 220 is straight hemmed tab 225. As can be seen from FIG. 2, both angled and straight hemmed tabs 220 and 225 extend from the outer edge of track 210 b. In a preferred embodiment a foam seal or other insulation is placed between track 210 a and track 210 b as they coupled. Furthermore, in a preferred embodiment, a fastener 230 (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener) is used to secure track 210 a to track 210 b once the two tracks are coupled together. Both tracks 210 a and 210 b are preferably made of 20 or 24 gage steel, however other materials can be used. FIG. 3 depicts an embodiment of bottom tracks 335 and top tracks 340. In a preferred embodiment, bottom track 340 is coupled to the bottom edge of each panel 105 and top track 340 is coupled to the top edge of each panel 105. Preferably, both bottom track 335 and top track 340 are “C” shaped double tracks. Bottom track 335 and top track 340 preferably couple to panel 105 with fasteners 345 (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener). Bottom track 335 and top track 340 preferably also couple to the floor and roof with fasteners.

FIG. 4 depicts another embodiment of an exterior wall 450. Exterior wall for example may be comprised of two panels 105 and entrance 455. Another number of panels 105 and entrances 455 can be used in any order. Entrance 455 is preferably made of the same material as panels 105, however, entrance 455 also includes a door or other entranceway. In FIG. 4, entrance 455 is shown as 4 feet wide by 8.5 feet tall, however another size panel can be used. Preferably, entrance 455 has the same height as panels 105.

FIG. 5 depicts an example of a temporary structure floor plan. As can be seen in the figure, the floor plan is a rectangular structure having two parallel long walls made up of four panels 105 each and two parallel short walls made up of two panels 105 and one entrance 455 each. The configuration shown in FIG. 5 is merely exemplary and another number of panels 105 and entrances 455 can be used to define the structure. Additionally, structures can be assembled in multiples or stacked as needed. Furthermore, structures need not be rectangular, but can have another shape.

FIG. 6 depicts the self-locking corner 660 used to couple perpendicular sections of wall. Self-locking corner 660 is preferably used to couple a track 210 b of a first panel 105 to a track 210 a of a second, perpendicular panel 105. Self-locking corner 660 is preferably coupled to tracks 210 a and 210 b with a fastener (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener). A foam seal or other insulation can be used between tracks 210 a and 210 b to improve the insulation of the structure.

FIG. 7 depicts roof and floor panels 765. Preferably roof and floor panels 765 are made of the same materials as panels 105. As shown in FIG. 7, roof and floor panels 765 are preferably 8 feet by 10 feet, however other dimensions can be used. In the preferred embodiment, each roof and floor panel 765 is coupled on two sides with track 210 a and on two sides with track 210 b, however other configurations can be utilized. Preferably, the roof is supported by beams. The beams preferably span the 20 foot section of the structure and are placed at 4 foot or 8 foot intervals, however other distributions and sizes of the beams can be used.

FIG. 8 depicts exterior wall sections 870 with cross beam roof supports at intervals. Exterior wall sections 870 are the same as panels 105, except exterior wall section 870 are able to be coupled to roof beams 875. In the preferred embodiment, wall sections 870 are installed down both sides of the temporary structure. Numerous configurations can be implemented to divide the structure into rooms by using panels such as section 870. Additional temporary structures can be coupled to the first temporary structure to create longer, wider, or stacked (e.g. two story) structures. The additional temporary structures can be coupled to the first temporary structure either side by side, end to end, or one on top of another.

FIGS. 9 a-b depict an embodiment of a coupling device 909 for coupling a wall panel coupled to track 210 a to a floor panel coupled to track 210 b. Coupling device 909 is substantially “C” shaped. As can be seen in FIG. 9 b, the upper portion of coupling device 909 mates with track 210 a and there is a flange that couples to straight hemmed tab 225 of track 210 b. Coupling device 909 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener 908 engages coupling device 909 and track 210 a securely coupling the wall panel to the floor panel. Fastener 908 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

FIGS. 10 a-b depict an embodiment of a coupling device 1011 for coupling a wall panel coupled to track 210 b to a roof panel coupled to track 210 b. Coupling device 1011 is substantially “C” shaped. As can be seen in FIG. 10 b, the upper portion of coupling device 1011 has a flange that mates with the angled hemmed tab of the track 210 b of the roof panel while the lower portion of coupling device 1011 mates with track 210 b of the wall panel. Coupling device 1011 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener 1012 engages coupling device 1011 and track 210 b of the wall panel securely coupling the wall panel to the roof panel. Fastener 1012 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

FIGS. 11 a-b depict an embodiment of a coupling device 1116 for coupling a wall panel coupled to track 210 b to a roof panel coupled to track 210 a. Coupling device 1116 is substantially “C” shaped. As can be seen in FIG. 11 b, the upper portion of coupling device 1116 surrounds track 210 a of the roof panel, while the lower portion of coupling device 1116 abuts with track 210 b of the wall panel. Coupling device 1116 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners 1117 engage coupling device 1116 and both track 210 b of the wall panel and track 210 a of the roof panel, securely coupling the wall panel to the roof panel. Fasteners 1117 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

FIGS. 12 a-b depict an embodiment of a coupling device 1221 for coupling two roof panels to a beam 1223. Coupling device 1221 is substantially “A” shaped. As can be seen in FIG. 11 b, the upper portion of coupling device 1221 fits within the indented portion 215 of track 210 a and over angled hemmed tab 220 of track 210 b, while the lower portion abuts beam 1223. Coupling device 1221 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener 1222 engages coupling device 1221 and beam 1223, securely coupling the roof panels to the beam 1223. Fastener 1222 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

FIGS. 13 a-b depict an embodiment of a coupling device 1333 for coupling two perpendicular wall panels at a corner. Coupling device 1333 is substantially “C” shaped. As can be seen in FIG. 13 b, the left portion of coupling device 1333 mates with track 210 a of a first wall panel, while the right portion of coupling device 1333 abuts track 210 b of the second wall panel. Coupling device 1333 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners 1334 engage coupling device 1333 and both track 210 a of the first wall panel and track 210 b of the second wall panel, securely coupling the wall panels. Fasteners 1334 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

FIGS. 14 a-b depict an embodiment of a coupling device 1442 for coupling two perpendicular wall panels at a corner. Coupling device 1442 is substantially “C” shaped. As can be seen in FIG. 14 b, the upper portion of coupling device 1442 mates with track 210 a of a first wall panel, while the lower portion of coupling device 1442 abuts track 210 b of the second wall panel. Coupling device 1442 is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners 1443 engage coupling device 1442 and both track 210 a of the first wall panel and track 210 b of the second wall panel, securely coupling the wall panels. Fasteners 1442 can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener.

In the preferred embodiment, each of the components of the temporary structure is manufactured off-site, and then the components are delivered to the site of the temporary structure where they are assembled. Preferably, the temporary structure can be assembled and disassembled with minimum effort and tools. Furthermore, the components can be reused so that the structure is re-locatable. Preferably, during assembly, each fastener is installed either from the inside of the structure or from the roof of the structure.

FIGS. 15 a-b depict all of the components for an approximately 20′×40′ temporary structure fit within a standard 20 foot shipping container for transportation. In locations where wind is an issue, traditional anchors and tie downs can be used to secure the temporary structure. In the preferred embodiment, the roof can support at least a 40 lb load, however in other embodiment the roof can support greater loads.

Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all publications, U.S. and foreign patents and patent applications, are specifically and entirely incorporated by reference. It is intended that the specification and examples be considered exemplary only with the true scope and spirit of the invention indicated by the following claims. Furthermore, the term “comprising” includes the terms “consisting of” and “consisting essentially of,” and the terms comprising, including, and containing are not intended to be limiting. 

1. A system for constructing a temporary structure, comprising: a plurality of wall panels; a plurality of roof panels; a plurality of floor panels; at least one door panel; and one or more wall panel, roof panel, floor panel and door panel comprising at least one edge coupled to a first track and at least one edge coupled to a second track; wherein the first track has a first surface with an indentation and a flat second surface; and wherein the second track has an angled hemmed tab extending therefrom that is adapted to mate with the indentation of the first track and a straight hemmed tab extending therefrom that is adapted to abut the flat second surface of the first track.
 2. The system of claim 1, further comprising a plurality of fasteners, wherein each fastener is adapted to couple at least two of a wall panel, a roof panel, a floor panel, and a door panel.
 3. The system of claim 1, further comprising a plurality of coupling devices.
 4. The system of claim 3, wherein at least one coupling device is adapted to couple a wall panel to a floor panel.
 5. The system of claim 3, wherein at least one coupling device is adapted to couple a wall panel to a roof panel.
 6. The system of claim 3, wherein at least one coupling device is adapted to couple two wall panels perpendicularly.
 7. The system of claim 3, further comprising at least one roof support beam, wherein the coupling device is adapted to couple two wall panels and a roof support beam.
 8. The system of claim 1, wherein the wall panels, the roof panels, the floor panels, and the at least one door panel are identical.
 9. The system of claim 1, further comprising a coating on the surface of at least one panel.
 10. The system of claim 1, wherein each wall panel, roof panel, floor panel, and door panel has two first tracks and two second tracks.
 11. The system of claim 10, wherein the two first tracks are coupled adjacent to each other and the two second tracks are coupled adjacent to each other.
 12. The system of claim 1, wherein the system is adapted to be assembled and disassembled into the original components on location.
 13. The system of claim 12, wherein the system is adapted to be re-located and reassembled after being disassembled.
 14. The system of claim 1, wherein the first track and the second track are coupled to parallel edges.
 15. The system of claim 1, further comprising adhesive to adjoin panels.
 16. A structure, comprising: a plurality of wall panels; a plurality of roof panels; a plurality of floor panels; at least one door panel; and one or more wall panel, roof panel, floor panel, and door panel comprising at least one edge coupled to a first track and at least one edge coupled to a second track; wherein the first track has a first surface with an indentation and a flat second surface; and wherein the second track has an angled hemmed tab extending therefrom that is adapted to mate with the indentation of the first track and a straight hemmed tab extending therefrom that is adapted to abut the flat second surface of the first track.
 17. The structure of claim 16, further comprising a plurality of fasteners, wherein each fastener couples at least two of a wall panel, a roof panel, a floor panel, and a door panel.
 18. The structure of claim 16, further comprising a plurality of coupling devices.
 19. The structure of claim 18, wherein at least one coupling device couples a wall panel to a floor panel.
 20. The structure of claim 18, wherein at least one coupling device couples a wall panel to a roof panel.
 21. The structure of claim 18, wherein at least one coupling device couples two wall panels perpendicularly.
 22. The structure of claim 18, further comprising at least one roof support beam, wherein the coupling device couples two wall panels and a roof support beam.
 23. The structure of claim 16, wherein the wall panels, the roof panels, the floor panels, and the at least one door panel are identical.
 24. The structure of claim 16, further comprising a coating on the surface of at least one panel.
 25. The structure of claim 16, wherein each wall panel, roof panel, floor panel, and door panel has two first tracks and two second tracks.
 26. The structure of claim 25, wherein the two first tracks are coupled adjacent to each other and the two second tracks are coupled adjacent to each other.
 27. The structure of claim 16, wherein the structure is disassemblable into the original components.
 28. The structure of claim 27, wherein the structure is re-locatable and reassemblable.
 29. The structure of claim 16, wherein the first track and the second track are coupled to parallel edges.
 30. The structure of claim 16, further comprising adhesive between adjoining panels.
 31. A panel, comprising: a first track coupled to at least one edge of the panel; and a second track coupled to at least one other edge of the panel; wherein the first track has a first surface with an indentation and a flat second surface; and wherein the second track has an angled hemmed tab extending therefrom that is adapted to mate with the indentation of the first track and a straight hemmed tab extending therefrom that is adapted to abut the flat second surface of the first track. 